Condition Monitoring

for efficient
Life Cycle Cost
Management.

E 10.122.0/04.07
Headquarters Germany
Your professional Partner
for Condition Monitoring.
With over 4,000 employees worldwide, HYDAC is one
of the leading suppliers of fluid technology,
hydraulic and electronic equipment.

HYDAC China
We are the professional partner in the area
of Condition Monitoring. Our knowledge and skill
combined with our high level of research
and development capabilities means
that we are on the same wavelength
as our customers. We offer complete

HYDAC Danemark
systems and components to monitor
industrial and mobile machines.

Global
yet local.
With 40 overseas
subsidiaries and over
500 distributors and
service partners,

HYDAC USA
HYDAC is your reliable
partner worldwide.

System solutions.
One supplier.

HYDAC India
One contact.
Wherever you need us,
we are there to help you
find the most effective solution –
for every application,
from components
to a complete system.

HYDAC France
HYDAC Brasil

E 10.122.0/04.07
HYDAC Australia
2
 Contamination

Life Cycle Cost Viscosity Change

Management by
HYDAC Condition Monitoring. Water

Condition Monitoring is the collection and interpretation of data from machines,

systems and their components, with the aim of conducting predictive maintenance Pressure
programs based on the system condition.
The term Life Cycle Cost (LCC) describes the cost analysis of a machine cycle
or facility cycle from acquisition to decommissioning. The goal to reduce costs is Temperature
the future focus of machine manufacturers and users. A promising and efficient solution
to reduce the LCC arises from applying modern Condition Monitoring systems
to fluid power equipment.
Volume
To reach this goal HYDAC offers an extensive product programme
of components and systems as well as application specific service activities.
It includes solutions for all areas of Condition Monitoring systems:
Dielectric Constant
Change
Data acquisition, Interpretation, Monitoring /Control
The approach is suitable for the operator, service provider,
maintenance engineer and machine manufacturer. Total Acid Number

Applications
Hydraulic
Lubrication

Philosophy. Integration Concept.

Applications Data acquisition
The operation data of the machine or system are
measured continuously by a variety of sensors:

Process Data / Fluid Data / Machine Data

Process data
(e.g. pressure, temperature, flow rate, liquid level ...)
Fluid data
Data Acquisition Interpretation
(e.g. contamination, water content, viscosity ...)
Machine data
(e.g. start/stop, cycle time, energy,
consumption, errors ...)

Data Transfer

E 10.122.0/04.07
Service Maintenance Monitoring Control

3
 CS 1000 CSI-D-5
FMMP AS 1000 USB
FluidMonitoring Adapter Unit
Module Pressure
Contamination

Water HYDACLab® CSI-B-1

Temperature 4x 4...20 mA
Viscosity Change
Dielectric Constant
FMM Change
FluidMonitoring ZBM Flow
Module AS 1000
Water
Temperature

CSI-C-4
Frequency-
modulated
EVS 3100

Volume Rate

FMMHP CSI-F-10
FluidMonitoring Module
High Pressure HDA 4000
GSM
Pressure

ETS 4000
CSI-B-2
Temperature RS232

VL 2 GW

Contamination

Hydraulic Adaption Sensors HSI Electrical

Couplings, Adapters, Manifolds Measurement of Process Data and Fluid Data HYDAC Interfaces
Sensor Condition Sensor
Interface Interfaces CSI

Product Programme.
Interpretation The CM programme is characterised by the following
features:
The gathered data is analysed and interpreted
using HYDAC’s long standing experience in Modular open structure / easily expanded if needed
Fluidengineering. The interpretation of process, Open hardware structure / not exclusive to one producer
fluid and machine data provides a much deeper Offline / online architecture
understanding of the system condition than
conventional limited monitoring. Universal integration capability

In addition to sensors to measure the essential

Monitoring / Control
Finally the simplified data in various forms
is presented to the operator. This enables him
to optimally monitor and control the machine.
A corresponding service message or activity
is initiated.
Service concepts
This condition based monitoring procedure
will lead the machine operator or manufacturer
to better service decisions.
data in fluid power applications the HYDAC product
programme includes modules and interfaces
for simple system integration:
Mechanical Conditioning Modules
(e.g. couplings, adapters, manifolds ...)
FMM - Modules
- Adjusting of the necessary flow rate
- Combines different connection possibilities
for CS 1000, AS 1000 and HYDACLab®
- Easy integration capability

E 10.122.0/04.07
4
 FCU 1000

MDE 6070

Service
CMU 1000

HMG 500 HMG 3000

CM-EXPERT

HDA 5500

Interpretation Monitoring / Control Service

Visualisation / Recording / Analysis Fluidengineering /
Communication / Interaction Fluidservice / Maintenance /
Training

Sensors (process data, fluid data) Interpretation (Visualisation, Recording,

® Analysis, Algorithms ...)
HYDACLab – Oil Condition Sensor
- Rel. change in viscosity: ± 30 % of initial value CMU 1000 – ConditionMonitoring Unit
- Rel. change in dielectric: ± 30 % of initial value - Real time controller for data analysis
- Rel. humidity: 0 ... 100 % saturation - 8 analogue input signals or HSI components
- Temperature: -25 ... 100 °C - Interfaces: RS 232, Ethernet (RJ45), ...
- Output signal: sequential 4 ... 20 mA, switching output, HSI - Switching outputs
- Operating range: 0 ... 50 bar - Parameterisation with PC-USB interface
- Data storage: SRAM, Flash, USB stick
CS 1000 – ContaminationSensor
- ISO4406 (1999/1987), NAS 1638, SAE AS 4059 MDE 6070 – CM-Expert
- Output signal: 4 ... 20 mA, 0 ... 10 V, RS 485, relay output, HSI - Industrial PC
- Operating range: 0 ... 300 bar, 0 ... 85 °C - 52 signal inputs single wire or RS 485 (extendable)
- All industrial interfaces
VL 2 GW: DirtController - Up to 15 plug-in modules (analogue and binary,
- Inlet pressure (up to 25 bar) in-/outputs: frequency, particles, relay ...)
- Differential pressure (up to 5 bar)
- Output signal: 4 ... 20 mA, relay outputs FCU 1000 – FluidControl Unit
- Operating range: -40 ... 85 °C - Portable service unit for temporary measurement
of solid particle contamination and water content
AS 1000 – AquaSensor - Integrated pump allows the operation
- Rel. humidity: 0 ... 100 % saturation at pressureless reservoirs
- Temperature: -25 ... 100 °C - Internal data memory and PC communication
- Output signal: 4 ... 20 mA

E 10.122.0/04.07
- Fluids up to 350 mm2/s
- Operating range: 0 - 50 bar

Sensors- and Communication Interfaces

(e.g. 4 - 20 mA, 0 - 10 V, relay outputs, CAN, Ethernet, GSM, USB ...)
5
Customer Benefits. Application fields.
Permanent monitoring and documentation Aerospace
of the machine process
Automotive industry
Automatically generated warning of reaching
Food industry
pre-determined data levels
Laboratory and inspection systems
Immediate alert of overshooting critical safety levels
Machine tools industry
Avoiding early failures and consequential damage
Machining centres
Use the full life cycle capacity of the components
Medical technology
Support for redesign work
Mining
Increasing the machine availability
Mobile hydraulics
Optimisation of the safety and quality levels
Oil and gas
of the machine process
Paper industry
Optimisation of the maintenance and service
activities Pharmacy
Demand oriented use of material- and personal Plastics machines
recourses Power stations
Support in case of damage: claim management Semiconductor industry

E 10.122.0/04.07
Life Cycle Cost Management by Steel plants
HYDAC Condition Monitoring
Transfer presses
Wind power
6
 Fluidengineering
and Service –
worldwide.
Fluidengineering for optimisation,
maintenance and training.
The complete package of
technical service:

Service Centre
Maintenance and commissioning
Overhaul and repair
Analysis
(e.g.: Oil and cooling lubricant analysis)

Development and Design

Highly focused and market-oriented
State of the art technology
and international approvals

Training Centre
Structured and comprehensive
knowledge about hydraulics,
measuring technology and maintenance
On site training with our customers

E 10.122.0/04.07
7
Broch.: Cooling Systems DEF 5.700../.. Brochure: Electronics 18.000../.. Brochure: Accessories DEF 6.100../.. Brochure: Compact Hydraulics DEF 5.300../.. Brochure: Systematic Fluid Service DEF 7.929../.. Br.: Filters for Industrial Processing DEF 7.700../.. Brochure: Filtration Range DEF 7.000../.. Brochure: Accumulators DEF 3.000../..
HYDAC Companies
HYDAC Headquarters

HYDAC Distributors and Service Partners

GMBH
Head Office
HYDAC INTERNATIONAL

Fax:
Phone:
Germany
Industriegebiet
Local expertise.

+49 (0)6897/509-324
66280 Sulzbach/Saar

+49 (0)6897/509-1309
www.hydac.com
Global presence.

Internet: www.hydac.com
E-Mail: service@hydac.com

E 10.122.0/04.07